CORNER CONNECTOR

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to and the benefit of U.S. patent application Ser. No. 18/619,059 filed on 27 Mar. 2024.

TECHNICAL FIELD

The disclosure relates generally to construction of building structures, and more particularly to connectors used to couple structural members to each other in the construction of such building structures.

BACKGROUND

Connection brackets function to simplify and strengthen the union of orthogonal and non-orthogonal members of various structures, such outdoor decks, pavilions, gazebos, pergolas, or other structures useful for providing shade, cover, or privacy. Most commonly, these connection brackets are made of metal and the members themselves are most commonly made of dimensional lumber.

In U.S. Pat. No. 949,394, Daly describes a device comprising a plurality of three-sided tubes orthogonally oriented to each other and welded into a unitary assembly. In U.S. Pat. No. 2,931, 129, Boniface teaches to weld tubes in various configurations to form a unitary bracket that accepts elongate dimensional lumber. It is proposed by Boniface that construction of framed shed-like structures is facilitated by such a plurality of arranged unitary brackets. In U.S. Pat. No. 4,076,431, Burvall teaches how to build framed structures with a sloped roof and common ridge using universal connecting brackets. These structures being coverable with canvas or other similar fabric to provide protection against rain or snow. In U.S. Pat. No. 10,858,819, Styrc teaches to weld the terminal ends of a plurality of metal tubes oriented in a common plane against a central orthogonal tube to create a unitary assembly into which posts (generally dimensional lumber) are fitted.

Devices disclosed in the prior art can be used for construction of modular structures for providing shade, cover, or privacy, by arranging unitary connectors in a desired manner and coupling the resulting arrangement of unitary connectors to each other using structural members, such as dimensional lumber.

The unitary connectors are commonly welded as a finished good and occupy a significant volume of space. Many of these modular assemblies are quite large and must be shipped in large boxes with low weight to volume ratios which generally increases shipping costs. A variety of unitary connector types need to be stocked by sellers to accommodate the variety of connection types, e.g. a four-corner connection, or an angled roof truss connection. Users, such as contractors and builders, need to carefully plan to determine the types of connectors needed in a particular construction. Variants may need to be included to account for unexpected situations arising during constructions. For large constructions, specialized delivery to the construction site may be needed, increasing costs and delays in construction.

Generally, once a structure is built using connectors, it is not particularly amenable to modification. For example, in order to add a horizontal post to a pre-existing vertical post, the structure may need to be dismantled in order to replace the connector with a connector accommodating the additional horizontal post.

In some cases, unitary connectors, partially modular connectors, partially assembled modular connectors are desirable. For example, modular components may be used to partially construct a partially modular connector, which may then be sold to an end user.

In many cases, structure performance of a connector is an important consideration. Due to limited access to advanced tools and the need to reduce working time, modular connectors are made to be easy to assemble, e.g. end users are generally not willing to weld components to form a connector due at least to the time required and the need for welding equipment. Such ease may come at the cost of structural performance and undesirable geometry of connectors. For example, fully modular connectors may end up with greater gaps and protrusions than a pre-constructed connectors. Such gaps and protrusions may interfere with user operation after construction. For example, modular connectors may have relatively low rigidity.

Improvement is desired.

SUMMARY

It is found that problems discussed herein may be solved by using a modular connector that may be readily assembled and/or reconfigured into different configurations. For outdoor structures like pergolas, pavilions, or gazebos the most common assembly (or structure) is a three-post corner assembly comprising a vertical post (or member) and two horizontal orthogonal posts (or members). Other assemblies include a vertical post with two, four, or five horizontal orthogonal posts or two non-orthogonal posts. For such a modular connector, it is desirable to achieve a large number of configurations of the modular connectors using as a few unique parts as possible so as to allow building of a large variety of structures.

Advantageously greater design flexibility may be achieved, including the ability to add on to an existing structure without having to dismantle and rebuild a structure. For example, a user that initially installed a four-post pergola structure using three-post corner connection assemblies may later decide to extend the length of the structure. The modular connector disclosed herein may permit horizontal sleeves to be easily added to the three-post assemblies converting them to four-post connection assemblies with a pleasing aesthetic appearance. For example, a weld-free appearance may be readily achieved.

It is found partially modular connectors may provide similar advantages. It is found that a pre-constructed corner connector, comprising three sleeves and comprising modular flexibility to attach a fourth sleeve, may be achieved by the use of plurality of interconnecting or interleaving angle brackets to form one side of the corner connector and a sheath to form an opposing side of the corner connector. Projections extending from the angle brackets may overlap or abut each other to mitigate movement, which may advantageously improve rigidity of the constructed corner connector. Such overlapping projections may extend in a plurality of non-parallel direction to mitigate movement in two or three non-parallel directions. Additional rigidity may be achieved by welding of edges formed between angle brackets. Advantageously, a substantially continuous, i.e. lacking gaps or protrusions interfering with user operation, rigid, readily deployable three-sleeved corner connector that is flexibly and modularly expandable to a four-sleeved corner connector may be achieved.

Accordingly, in some aspect(s) herein, there is disclosed a corner connector to connect a first frame member, a second frame member, and a third frame member to each other to form a tubular corner of a structure. The corner connector comprises a first angle bracket directly attached to the first frame member, including a first projection and a first bottom slot formed on respective opposite arms of the first angle bracket; a second angle bracket directly attached to the second frame member proximal and non-parallel to the first frame member, including a second projection and a second bottom slot formed on respective opposite arms of the second angle bracket, a side slot dimensioned according to the first projection to securably receive the first projection therethrough into an interior of the tubular corner to couple the first angle bracket to the second angle bracket and to define a first end of the tubular corner; a third angle bracket directly attached to the third frame member proximal and non-parallel to each of the first and second frame members, including a plurality of projections dimensioned according to the first bottom slot and the second bottom slot, the plurality of projections being securably received through the first bottom slot and the second bottom slot into the interior to overlap the first projection and the second projection to improve rigidity of the corner connector by obstructing the first and the second projections to mitigate movement of the first and the second angle brackets; and a rigid sheath attached to and extending opposite to the first, the second, and the third angle brackets to form a second end of the tubular corner and to form first, second, and third sleeves for respectively receiving the first, the second, and the third frame members.

Implementations may include one or more of the following features. The first end of the tubular corner includes an inner spine of the tubular corner and the second end of the tubular corner includes an outer spine of the tubular corner. Overlapping of the first and the second projections mitigates movement of the first and the second angle brackets along a first direction, the first angle bracket includes a first bottom projection, the second angle bracket includes a second bottom projection overlapping the first bottom projection in the interior to mitigate movement of the first and the second angle brackets along a second direction non-parallel to the first direction. The first bottom projection is fastened to the second bottom projection. Each of the first projection, the second projection, the first bottom projection, and the second bottom projection is planar tabular-shaped. The first projection, the second projection, and the second bottom projection are mutually orthogonal planar plates. At least one of the first projection, the second projection, the first bottom projection, and the second bottom projection extends towards one of the first frame member, the second frame member, and the third frame member to cause abutment therewith to form a gap adjacent thereto in the interior. The sheath defines a plurality of slots suitable to receive a corresponding plurality of tabs of a fourth sleeve to couple the fourth sleeve to the corner connector. The sheath is welded to the first angle bracket, the second angle bracket, and the third angle bracket at outer edges of the corner connector. The sheath comprises three mutually orthogonal plates. The first frame member, the second frame member, and the third frame member are mutually orthogonal. The first angle bracket includes a first one or more apertures to allow fastening therethrough of the first frame member to the first angle bracket, the second angle bracket includes a second one or more apertures to allow fastening therethrough of the second frame member to the second angle bracket, and the third angle bracket includes a third one or more apertures to allow fastening therethrough of the third frame member to the third angle bracket. The plurality of projections are fastened to each of the first projection and the second projection.

Accordingly, in some aspect(s) herein, there is disclosed a structure. The structure comprises the corner connector described above, and the first frame member, the second frame member, and the third frame member.

Accordingly, in some aspect(s) herein, there is disclosed a method of constructing a corner connector to connect a first frame member, a second frame member, and a third frame member to each other to form a tubular corner of a structure.

Implementations may include one or more of the following features and/or steps. Receiving a first projection of a first angle bracket through a side slot of a second angle bracket to position the first projection inside the second angle bracket, to position a second projection of the second angle bracket inside the first angle bracket, and to secure the first angle bracket to the second angle bracket. Receiving a plurality of projections of a third angle bracket through a first bottom slot of the first angle bracket and a second bottom slot of the second angle bracket to secure the third angle bracket to the first angle bracket and the second angle bracket, the first bottom slot and the first projection being formed on opposite arms of the first angle bracket, the second bottom slot and the second projection being formed on opposite arms of the second angle bracket. Overlapping the plurality of projections against the first projection of the first angle bracket and a second projection of the second angle bracket to obstruct movement of the first angle bracket and the second angle bracket while the third angle bracket is secured to the first angle bracket and the second angle bracket. Attaching a rigid sheath to the first angle bracket to form a first sleeve suitable to receive the first frame member. Attaching the sheath to the second angle bracket to form a second sleeve suitable to receive the second frame member. Attaching the sheath to the third angle bracket to form a third sleeve suitable to receive the third frame member. Fastening the plurality of projections to each of the first projection and the second projection. Each of the first angle bracket, second angle bracket, third angle bracket, and sheath is of unitary construction. Attaching the sheath to the first angle bracket includes continuously joining the sheath to the first angle bracket to unitarily construct the first sleeve. Attaching the sheath to the second angle bracket includes continuously joining the sheath to the second angle bracket to unitarily construct the second sleeve. Attaching the sheath to the third angle bracket includes continuously joining the sheath to the third angle bracket to unitarily construct the third sleeve. Each of the first angle bracket, second angle bracket, third angle bracket, and sheath is composed of sheet metal. The sheath comprises a side sheath that defines an outer spine of the corner connector and a planar top sheath. Attaching the side sheath to the top sheath. Overlapping of the first and the second projections mitigates movement of the first and the second angle brackets along a first direction. Overlapping a first bottom projection of the first angle bracket and a second bottom projection of the second angle bracket inside the corner connector while the first angle bracket is secured to the second angle bracket to mitigate movement of the first and the second angle brackets along a second direction non-parallel to the first direction. Fastening the first bottom projection to the second bottom projection.

Accordingly, in some aspect(s) herein, there is disclosed a modular connector for coupling a first frame member to a second frame member at a predetermined angle. The modular connector also includes a first sleeve defining a first longitudinal axis and a first socket suitable to receive therein the first frame member, the first sleeve having an axially extending outer face, the outer face defining a plurality of slots thereon; and a second sleeve defining a second longitudinal axis, a terminal end along the second longitudinal axis, and a second socket suitable to receive therein the second frame member, the second sleeve including: a plurality of tabs extending away from the second socket from the terminal end, the plurality of tabs being receivable in the plurality of slots to position the second sleeve relative to the first sleeve, and an end plate extending from the terminal end towards the second socket to abut and fasten to the outer face of the first sleeve when each of the plurality of tabs is engaged with the plurality of slots to allow removable coupling of the first sleeve to the second sleeve, the end plate being angled relative to the second longitudinal axis to position the first frame member at the predetermined angle relative to the second frame member when the end plate is fastened in abutment to the outer face.

Implementations may include one or more of the following features. A first plurality of apertures is defined on the outer face and is complementary to a second plurality of apertures of the end plate, the first and second plurality of apertures being suitable to receive fasteners to allow engagement of the first sleeve with the second sleeve via the fasteners. Each of the first plurality of apertures is axially spaced apart from the plurality of slots and opens to the first socket to allow the fasteners to extend into the first socket via the first plurality of apertures to fasten the second sleeve to the first frame member. Each of the plurality of tabs is substantially non-parallel to the end plate. The plurality of tabs and the end plate are positioned at opposite lateral sides of the second sleeve. The plurality of tabs includes two spaced-apart tabs positioned at a common side of the second sleeve opposite to the end plate. The first sleeve includes a plurality of grooves extending from the outer face into the first socket to cause an interference fit between the first frame member and the first sleeve. Each of the plurality of grooves is suitable to receive a corresponding fastener to allow fastening of the first sleeve to the first frame member. A first plurality of apertures is defined on the outer face and is complementary to a second plurality of apertures of the end plate, the first and second plurality of apertures being suitable to receive fasteners to allow engagement of the first sleeve with the second sleeve via the fasteners, the first plurality of apertures being axially spaced apart from the plurality of slots, a groove of the plurality of grooves being positioned axially in-between the first plurality of apertures and the plurality of slots. Each tab of the plurality of tabs is interlockable with a corresponding slot of the plurality of slots. The first sleeve includes a stiffener extending at least partially across the first socket, and being spaced apart from the plurality of slots to prevent interference with the first frame member. The first sleeve defines a quadrilateral cross-section, the stiffener being triangularly shaped and extending across two sides of the quadrilateral cross-section. The end plate is a first end plate, the second sleeve including a second end plate extending from the terminal end towards the second socket and opposite to the first end plate to abut and fasten to the outer face of the first sleeve when each of the plurality of tabs is received in the plurality of slots. The plurality of tabs includes two spaced-apart tabs positioned at a common side of the second sleeve opposite to the first end plate, the second end plate being positioned between the two spaced-apart tabs.

Accordingly, in some aspect(s) herein, there is disclosed a structure. The structure also includes a first member, a second member, and a modular connector for coupling a first frame member to a second frame member at a predetermined angle. The modular connector also includes a first sleeve defining a first longitudinal axis and a first socket suitable to receive therein the first frame member, the first sleeve having an axially extending outer face, the outer face defining a plurality of slots thereon; and a second sleeve defining a second longitudinal axis, a terminal end along the second longitudinal axis, and a second socket suitable to receive therein the second frame member, the second sleeve including: a plurality of tabs extending away from the second socket from the terminal end, the plurality of tabs being receivable in the plurality of slots to position the second sleeve relative to the first sleeve, and an end plate extending from the terminal end towards the second socket to abut and fasten to the outer face of the first sleeve when each of the plurality of tabs is engaged with the plurality of slots to allow removable coupling of the first sleeve to the second sleeve, the end plate being angled relative to the second longitudinal axis to position the first frame member at the predetermined angle relative to the second frame member when the end plate is fastened in abutment to the outer face. The first frame member is the first member and the second frame member is the second member, the first member being received in the first sleeve, the second member being received in the second sleeve. The structure also includes a plurality of fasteners at least partially passing through the end plate, the outer face of the first sleeve, and the first member to cause frictional engagement therebetween to fasten the first sleeve, the second sleeve, and the first member to each other.

Implementations may include one or more of the following features. Each of the plurality of fasteners is received in a corresponding one of a plurality of apertures defined in each of the end plate and the outer face. The first sleeve includes a first plurality of grooves extending from the outer face into the first socket to frictionally engage with the first member, the second sleeve including a second plurality of grooves extending into the second socket to frictionally engage with the second member, each groove of the first and second plurality of grooves receiving a corresponding fastener of the plurality of fasteners. Each of the plurality of fasteners is received in a corresponding one of a plurality of apertures defined in each of the end plate and the outer face, and a groove of the first plurality of grooves being spaced-apart from and positioned axially in-between the plurality of apertures and the plurality of slots.

Accordingly, in some aspect(s) herein, there is disclosed a sleeve of a modular connector for coupling a first frame member to a second frame member at a predetermined angle. The sleeve also includes and a plurality of slots defined on an axially extending outer face of the common sleeve, the sleeve being axially elongated and defining: an axially terminal end; a second socket suitable to engageably receive therein the second frame member; a plurality of tabs extending away from the second socket from the axially terminal end and receivable in the plurality of slots to position the sleeve relative to the common sleeve; and an end plate extending from the axially terminal end towards the second socket to abut and fasten to the outer face of the common sleeve when each of the plurality of tabs is received in the plurality of slots to allow removable coupling of the sleeve to the common sleeve, the end plate being angled to allow the first frame member to be positioned at the predetermined angle relative to the second frame member when the end plate is fastened in abutment to the outer face.

Implementations may include one or more of the following features. The sleeve may include a plurality of grooves extending laterally inwardly towards the second socket to cause an interference fit between the sleeve and the second frame member when the second frame member is received in the second socket. Each of the plurality of grooves defines an aperture for receiving a corresponding fastener to allow fastening of the sleeve to the second frame member, the sleeve may include a plurality of apertures suitable to receive a plurality of fasteners to allow engagement of the sleeve with the common sleeve and the first frame member via the fasteners. A first plurality of apertures is defined on the outer face and is complementary to a second plurality of apertures of the end plate, the first and second plurality of apertures being suitable to receive fasteners to allow engagement of the first sleeve with the second sleeve via the fasteners. Each of the first plurality of apertures is axially spaced apart from the plurality of slots and opens to the first socket to allow the fasteners to extend into the first socket via the first plurality of apertures to fasten the second sleeve to the first frame member. Each of the plurality of tabs is substantially non-parallel to the end plate. The plurality of tabs and the end plate are positioned at opposite lateral sides of the second sleeve. The plurality of tabs includes two spaced-apart tabs positioned at a common side of the second sleeve opposite to the end plate. The first sleeve includes a plurality of grooves extending from the outer face into the first socket to cause an interference fit between the first frame member and the first sleeve. Each of the plurality of grooves is suitable to receive a corresponding fastener to allow fastening of the first sleeve to the first frame member. A first plurality of apertures is defined on the outer face and is complementary to a second plurality of apertures of the end plate, the first and second plurality of apertures being suitable to receive fasteners to allow engagement of the first sleeve with the second sleeve via the fasteners, the first plurality of apertures being axially spaced apart from the plurality of slots, a groove of the plurality of grooves being positioned axially in-between the first plurality of apertures and the plurality of slots. Each tab of the plurality of tabs is interlockable with a corresponding slot of the plurality of slots. The first sleeve includes a stiffener extending at least partially across the first socket, and being spaced apart from the plurality of slots to prevent interference with the first frame member. The first sleeve defines a quadrilateral cross-section, the stiffener being triangularly shaped and extending across two sides of the quadrilateral cross-section. The end plate is a first end plate, the second sleeve including a second end plate extending from the terminal end towards the second socket and opposite to the first end plate to abut and fasten to the outer face of the first sleeve when each of the plurality of tabs is received in the plurality of slots. The plurality of tabs includes two spaced-apart tabs positioned at a common side of the second sleeve opposite to the first end plate, the second end plate being positioned between the two spaced-apart tabs.

Embodiments can include combinations of the above features. It is understood that one or more sleeves may be sold in packages or in kits.

Further details of these and other aspects of the subject matter of this application will be apparent from the detailed description included below and the drawings.

DESCRIPTION OF THE DRAWINGS

Reference is now made to the accompanying drawings, in which:

FIG. 1 is a perspective view of a modular connector, in accordance with an embodiment;

FIG. 2A is a perspective view of a primary sleeve of a modular connector, in accordance with an embodiment;

FIG. 2B is a front perspective view of the primary sleeve;

FIG. 2C is a side elevation view of the primary sleeve;

FIG. 3A is a rear perspective view of a secondary sleeve of a modular connector, in accordance with an embodiment;

FIG. 3B is a cross-sectional view, in perspective, through the line 3B-3B in FIG. 3A;

FIG. 3C is a top elevation view of the secondary sleeve;

FIG. 3D is a side elevation view of the secondary sleeve;

FIG. 3E is a perspective view of the secondary sleeve shown along with example fasteners;

FIG. 4A is a perspective view of a structure formed using the modular connector, in accordance with an embodiment;

FIG. 4B is a partial cross-sectional view of the structure in FIG. 4A;

FIG. 4C is a magnified view of the region 4C in FIG. 4B;

FIG. 5 is a perspective view of a primary sleeve with a cross-section thereof exposed, in accordance with an embodiment;

FIG. 6A is a perspective view of a holder mounted on a modular connector, in accordance with an embodiment;

FIG. 6B is an exploded perspective view of the holder;

FIG. 6C is a rear perspective view of the holder;

FIG. 6D is a front perspective view of the holder;

FIG. 7A is a perspective view of a modular connector, in accordance with another embodiment;

FIG. 7B is a perspective view of a modular connector, in accordance with a further embodiment;

FIG. 7C is a perspective view of a modular connector, in accordance with yet a further embodiment;

FIG. 7D is a perspective view of a modular connector, in accordance with yet another further embodiment;

FIG. 8 is a cross-sectional view, in perspective, of a secondary sleeve, in accordance with an embodiment; and

FIG. 9 is a partial perspective view of a secondary sleeve, in accordance with an embodiment;

FIG. 10A is a perspective view of a secondary sleeve, in accordance with an embodiment;

FIG. 10B is a rear elevation of the secondary sleeve of FIG. 10A.

FIG. 11A is a perspective view of a holder, in accordance with an embodiment;

FIG. 11B is an exploded perspective view of the holder of FIG. 11A;

FIG. 12A is an exploded perspective view of a secondary sleeve, in accordance with an embodiment;

FIG. 12B is a perspective view of the secondary sleeve of FIG. 12A;

FIG. 13 is a perspective view of a corner connector, in accordance with an embodiment;

FIG. 14A is a perspective view of a first stage of constructing the corner connector, in accordance with an embodiment;

FIG. 14B is a perspective view of a second stage of constructing the corner connector, in accordance with an embodiment;

FIG. 14C is a perspective view of a third stage of constructing the corner connector, in accordance with an embodiment;

FIG. 14D is a perspective view of a fourth stage of constructing the corner connector, in accordance with an embodiment;

FIG. 14E is a perspective view of a fifth stage of constructing the corner connector, in accordance with an embodiment;

FIG. 15A is a perspective view of a first stage of assembling a structure using a pre-constructed (or pre-assembled) corner connector and four frame members, in accordance with an embodiment;

FIG. 15B is a perspective view of a second stage of assembling the structure using the pre-constructed (or pre-assembled) corner connector and the four frame members;

FIG. 15C is a perspective view of a third stage of assembling the structure using the pre-constructed (or pre-assembled) corner connector and the four frame members;

FIG. 16 is a cross-sectional view along the line 16-16 in FIG. 15C, in accordance with an embodiment;

FIG. 17A is a plan, rear elevation, and side elevation view of an angle bracket, in accordance with an embodiment;

FIG. 17B is a rear elevation view of the angle bracket of FIG. 17A;

FIG. 17C is a side elevation view of the angle bracket of FIG. 17A;

FIG. 18A is a perspective view of an angle bracket, in accordance with an embodiment;

FIG. 18B is a rear elevation view of the angle bracket of FIG. 18A;

FIG. 18C is a side elevation view of the angle bracket of FIG. 18A;

FIG. 19A is a perspective view of an angle bracket, in accordance with an embodiment;

FIG. 19B is a front elevation view of the angle bracket of FIG. 19A;

FIG. 19C is a side elevation view of the angle bracket of FIG. 19A;

FIG. 20A is a perspective view of a top sheath, in accordance with an embodiment;

FIG. 20B is a plan view of the top sheath of FIG. 20A;

FIG. 21A is a perspective view of a side sheath, in accordance with an embodiment;

FIG. 21B is a plan view of the side sheath of FIG. 21A;

FIG. 21C is a side elevation view of the side sheath of FIG. 21A; and

FIG. 22 is a flow chart of an example method of constructing a corner connector to connect a first frame member, a second frame member, and a third frame member to each other to form a tubular corner of a structure.

DETAILED DESCRIPTION

Aspects of various embodiments are now described in relation to the figures.

FIG. 1 is a perspective view of a modular connector 100, in accordance with an embodiment.

The modular connector comprises a primary sleeve 102 (also referred to as a common sleeve or first sleeve), and secondary sleeves 104A, 104B, 104C.

The modular connector 100 is suitable for coupling a primary frame member 152 (also referred to herein as primary member 152) to a secondary frame member 154 (also referred to herein as secondary member 154) at a predetermined angle 156, as shown in FIG. 4A and as further described herein.

FIGS. 2A-2C are various views of an embodiment of the primary sleeve 102. FIG. 2A is a perspective view, FIG. 2B is a front perspective view, FIG. 2C is a side elevation view of the primary sleeve 102.

The primary sleeve 102 is elongated along a primary axis 106 (or first axis) so as to define a primary socket 108 (or first socket).

The primary socket 108 is suitable to receive the primary member 152. The primary socket 108 is suitable to engage with the primary member 152, e.g. the primary socket 108 may be configured to frictionally engage with the primary member 152.

The primary sleeve 102 may define one or more outer faces 112. The outer faces 112 may extend axially along the primary axis 106 (axially extending outer faces 112). A plurality of slots 110 may be formed on each outer face 112. The primary sleeve 102 may define a plurality of sides 118. The primary sleeve 102 may define four (lateral) sides 118, as shown in FIGS. 2A-2C. It is understood that the primary sleeve 102 may define more or less than four sides.

In various embodiments, the size and the shape of the primary sleeve 102 may be similar to the size and shape of the primary frame member 152 that is to be received in the primary sleeve 102.

A plurality of apertures 116 may be formed on the outer face 112 to open to the primary socket 108 to allow fasteners to pass therethrough to the primary frame member 152. Each of the first plurality of apertures 116 may be axially spaced apart from the plurality of slots 110.

The primary sleeve 102 may include a plurality of grooves 114 extending from the outer face 112 into the primary socket 108 to cause an interference fit between the primary frame member 152 and the primary sleeve 102, e.g. by biting into the primary member 152.

In various embodiments, the grooves 114 may be circular or non-circular depressions. In some embodiments, the grooves 114 may be elongated.

Each of the plurality of grooves is suitable to receive a corresponding fastener 120 (only four are shown in FIG. 2B for illustrative purposes) to allow fastening of the primary sleeve 102 to the primary frame member 152. In various embodiments, apertures may be provided in one or more of the plurality of grooves 114 to allow passage therethrough of a corresponding one of the fasteners 120 to fasten the primary sleeve 102 to the primary member 152. It was found to be particularly effective to fasten the primary sleeve 102 to the primary frame member 152 at the locations where the grooves 114 bite into (or press against) the primary sleeve 102.

As shown in FIG. 2C, in some embodiments, at least one groove 114 of the plurality of grooves 114 is positioned axially in-between the plurality of apertures 116 and the plurality of slots 110. Advantageously, positioning of the at least one groove 114 in-between the plurality of apertures 116 and the plurality of slots 110 may allow concealing of fasteners engaged with members via the at least one groove 114 once secondary sleeves is attached to the primary sleeve 102 adjacent to the at least one groove 114.

Two or more additional grooves 114 may be provided. For example, such grooves 114 may be axially spaced apart from each other by an offset 126. In various embodiments, the grooves may be spaced apart from one terminal end by a distance 124 of about 1 inch and spaced apart from another terminal end by a distance 122 of about 0.25 inch. Advantageously, offsetting grooves may help mitigate interference between fasteners that are driven through opposite sides, i.e. through grooves on opposite sides of (primary or secondary) sleeves. Advantageously, at least two grooves are provided to center and hold the member fixed in-placed via fasteners passing therethrough.

FIGS. 3A-3E are various views of an embodiment of a secondary sleeve 104, e.g. similar to one or more of the secondary sleeves 104A, 104B, 104B shown in FIG. 1.

FIG. 3A is a rear perspective view. FIG. 3B is a cross-sectional view, in perspective, through the line 3B-3B in FIG. 3A. FIG. 3C is a top elevation view. FIG. 3D is a side elevation view. FIG. 3E is a perspective view.

The secondary sleeve 104 is elongated along a secondary axis 136 to define a terminal end 138 along the secondary axis 136 and a secondary socket 134.

The secondary socket 134 is suitable to receive the secondary frame member 154. The secondary socket 134 may be suitable to engage with the secondary member 154, e.g. the secondary socket 134 may be configured to frictionally engage with the secondary member 154.

The secondary sleeve 104 includes an end plate 130 extending from about the axially terminal end 138 towards the secondary socket 134. The end plate 130 extends inwardly from an outer end of the secondary sleeve 104 in a lateral direction (laterally inwardly) to allow abutting and fastening of the end plate 130 to the outer face 112 of the primary sleeve 102 without needing an external fastening connection.

The end plate 130 may be angled relative to the secondary axis 136 to angle the primary frame member 152 at the predetermined angle 156 relative to the secondary frame member 154 (see angle 131 shown in FIG. 3B) when the end plate 130 is fastened in abutment to the outer face 112.

The secondary sleeve 104 may define a plurality of sides 128. The secondary sleeve 104 may define four (lateral) sides 128, as shown in FIGS. 3A-3E. It is understood that the secondary sleeve 104 may define more or less than four sides.

The secondary sleeve 104 includes a plurality of tabs 132 extending away from the secondary socket 134 from about the terminal end 138. In various embodiments, the plurality of tabs 132 may include two spaced-apart tabs 132 positioned at a common one of the sides 128 of the secondary sleeve 104 opposite to the end plate 130.

The plurality of tabs 132 are receivable in the plurality of slots 110 and may be complementary thereto. The plurality of tabs 132 may be complementarily receivable in the plurality of slots 110 to position the secondary sleeve 104 relative to the primary sleeve 102. In some embodiments, each tab 132 of the plurality of tabs 132 may be interlockable with a corresponding slot 110 of the plurality of slots 110.

In various embodiments, each of the plurality of tabs 132 may be substantially non-parallel to the end plate 130. In various embodiments, the plurality of tabs 132 may be angled relative to the end plate 130.

In various embodiments, the plurality of tabs 132 and the end plate 130 are positioned at opposite lateral sides (at an opposite pair of the sides 128) of the secondary sleeve 104.

Engagement of the plurality of tabs 132 with the plurality of slots 110 allows removable coupling of the primary sleeve 102 to the secondary sleeve 104 and positioning of the primary sleeve 102 relative to the secondary sleeve 104. When such positioning is achieved, the end plate 130 may be secured to the outer face 112 by fastening abutment thereof to the outer face 112.

In various embodiments, a supporting end plate 144 may be provided in addition to the end plate 130. The supporting end plate 144 may extend from about the terminal end 138 towards the secondary socket 134. The support end plate 144 may so extend opposite to the end plate 130 to abut and fasten to the outer face 112 of the primary sleeve 102 when each of the plurality of tabs 132 is received in the plurality of slots 110. In various embodiments, the supporting end plate 144 may be positioned between the two spaced-apart tabs 132.

In various embodiments, the end plate 130 and the supporting end plate 144 may be positioned at vertical ends (sides) of the secondary sleeve 104 in order to provide a reacting force and moment to forces and moments arising from the weight of the secondary member 154 while the same is attached to the primary member 152 via the modular connector 100 to be supported by the primary member 152.

A plurality of (end plate) apertures 140 may be formed on the end plate 130. The plurality of end plate apertures 140 (or apertures of the end plate) may be complementary to the plurality of apertures 116 of the primary sleeve 102 so as to receive fasteners 142. The primary sleeve 102 and the secondary sleeve 104 may be engaged with each other via the fasteners 142. In various embodiments, the fasteners 142 may be threaded fasteners such as screws or non-threaded fasteners such as rivets.

The secondary sleeve 104 may have formed thereon grooves 146 that extend into the secondary socket 134 to cause an interference fit between the secondary frame member 154 and the secondary sleeve 104, e.g. by biting into the secondary member 154.

In various embodiments, apertures may be provided in one or more of the plurality of grooves 146 to allow passage therethrough of a corresponding one of the fasteners to fasten the secondary sleeve 104 to the secondary frame member 154. It was found to be particularly effective to fasten the secondary sleeve 104 to the secondary frame member 154 at the locations where the grooves 146 bite into the secondary sleeve 104.

The secondary sleeve 104 may have formed thereon one or more holder slots 148 to engage with a holder 160, as shown in FIG. 6A and further described in these paragraphs.

The first and secondary sleeves 102, 104 may be formed by bending of sheet metal. For example, a sheet metal of a predetermined length, width and thickness (e.g. 2 mm thickness) may be bent along three (parallel) lines on the sheet metal to form a sleeve with a quadrilateral (rectangular) cross-section. As shown in FIGS. 2B, 3A, three of the four corners of the cross-sections of the respective sleeves 102, 104 may be defined by metal bent into a corner with a prescribed radius while one of the four corners may be butt-joint or other type of joint between two ends of the sheet metal.

It is found that the grooves 146 of the secondary sleeve 104 need not be as deep as the grooves 114 of the primary sleeve 102. For example, since the primary sleeve 102 may be cross-sectionally larger than the secondary sleeve 104, the depressions formed in the primary sleeve 102 may be deeper than depressions formed in the secondary sleeve 104. The depth of the depressions may be configured so as to formed a sufficient frictional fit with the secondary member 154.

In various embodiments, the secondary sleeve 104 may be generally smaller than the primary sleeve 102. For example, improved mating between the primary sleeve 102 and the secondary sleeve 104 may thereby be achieved.

FIG. 4A is a perspective view of a structure 150 formed using the modular connector 100, in accordance with an embodiment.

The modular connector 100 is coupled to the frame members 152, 154 to form the structure 150 and to rigidly couple the frame members 152, 154 at a predetermined angle 156 to each other.

The primary sleeve 102 of the modular connector 100 (the socket 108) receives the primary member 152 and the secondary sleeve 104A (the socket 134) of the modular connector 100 receives the secondary member 154. As shown in FIG. 4A, the secondary sleeves 104B, 104C are shown without frame members received therein (in sockets thereof). It is understood that members may be engagingly received in one or more of the secondary sleeves 104B, 104C to form the structure 150 and/or one or more of the secondary sleeves 104B, 104C may be disconnected from the modular connector 100 to reconfigure the modular connector 100.

The primary and secondary sleeves 102, 104A may be frictionally engaged with the respective primary and secondary members 152, 154.

The plurality of grooves 114, 146 press against, and form an interference fit with, the respective primary and secondary members 152, 154. The plurality of grooves 114, 146 are frictionally engaged with the respective primary and second members 152, 154 so as to center and hold the members 152, 154 firm once these are fastened in-place. As described previously, each groove of the plurality of grooves 114, 146 receive a corresponding fastener, e.g. such fasteners may pass through apertures formed in the grooves 114, 146 and the respective primary and secondary members 152, 154. Each of the plurality of grooves 114, 146 may be substantially circular and/or curved inwardly (to form a concave depression) to cause self-alignment of fasteners into apertures formed therein.

The primary sleeve 102 and the secondary sleeve 104A are fastened to each other via the plurality of apertures 116, 140. The plurality of apertures 116, 140 may be suitable to receive the fasteners 142 to allow engagement of the primary sleeve 102 with the secondary sleeve(s) 104A, 104B, 104C, as well as the primary frame member 152 via the fasteners 142. The plurality of fasteners 142 pass at least partially through the end plate 130, the outer face 112, and the primary frame member 152 to cause frictional engagement therebetween to fasten the primary sleeve 102, the secondary sleeve 104A, and the primary member 152 to each other. The structure 150 is then formed by coupling the secondary member 154 to the modular connector 100.

FIG. 4B is a partial cross-sectional view of the structure 150.

Fasteners coupling the end plates 130, 144 to the outer face 112, the primary sleeve 102 to the primary member 152, and the secondary sleeve 104A to the secondary member 154, are not shown in FIG. 4B.

In various embodiments, as shown in FIG. 4A-4B, the primary sleeve 102 (and frame member configured to engage therewith) is substantially vertical, while the secondary sleeves 104A, 104B, 104C are non-parallel thereto and hence are at least partially non-vertical. For example, the primary sleeve 102 may be a vertical sleeve and the secondary sleeves 104A, 104B, 104C are horizontal sleeves. As shown in FIG. 4A, the secondary sleeves 104A, 104B, 104C are substantially orthogonal to the primary sleeve 102.

When attached to the primary sleeve 102 and mounted in the structure 150, the secondary sleeves 104A, 104B, 104C provide resistance to torque and forces arising due to the weights of the frame members to mitigate failure of the modular connector 100, as indicated by the illustrative line arrows in FIG. 4B.

The primary sleeve may include a stiffener 158 or reinforcement bracket. The stiffener 158 may be disposed above the frame member 152 and may be integrally coupled to and/or in unitary construction with the primary sleeve 102. For example, the stiffener 158 may be fastened using a fastener and/or welded to the primary sleeve 102. The stiffener 158 may serve to stiffen and strengthen the primary sleeve 102, and the modular connector 100. In some embodiments, the stiffener 158 may function as a stop to ensure that the member 152 is engaged with the primary sleeve 102 via the open-end thereof while hindering passage of the member 152 beyond the stiffener 158 as the member 152 is inserted into the primary sleeve 102.

FIG. 4C is a magnified view of the region 4C in FIG. 4B.

As shown by the illustrative line arrows in FIG. 4C, as weight is applied to the secondary sleeve 104A, an end of thereof that is distal from the primary sleeve 102 bends downwards so as to push the plurality of tabs 132 into the primary member 152, which generates a force and/or moment reaction to the weight, and to push an outer portion of the supporting end plate 144 into the primary sleeve 102 by pulling an inner portion of the supporting end plate 144 that is fastened to the primary member 152 away from the primary sleeve 102, which also generates a force and/or moment reaction to the weight. Advantageously, by generating opposing moments and forces, the risk of failure of the modular connector 100 may be mitigated.

FIG. 5 is a perspective view of a primary sleeve 102 with a cross-section thereof exposed, in accordance with an embodiment.

As shown in FIG. 5, the stiffener 158 extends at least partially across the socket 108. The stiffener 158 may be spaced apart from the plurality of slots 110 to prevent interference with the frame member 152.

The primary sleeve 102 may be define a rectangular cross-section across which the stiffener 158 is disposed. In some embodiments, the cross-section may be a non-rectangular quadrilateral cross-section. In various embodiments, with a quadrilateral cross-section, the stiffener 158 may be triangularly shaped and extend across two sides 118 of the primary sleeve 102 (and cross-section thereof). In various embodiments, the cross-section may be a non-quadrilateral polygon, and/or curved shape, e.g. the cross-section may be an elliptical or circular cross-section.

In various embodiments, the primary sleeve 102 may be open-ended or comprise a removable cap that is disposed over the stiffener 158 and coupled to the primary sleeve 102 to allow selective opening of the primary sleeve 102. Advantageously such selective opening may facilitate operations within the body of the primary sleeve, e.g. installation of stiffeners, fasteners, or other construction elements. Having a separate cap may facilitate manufacturing using sheet metal.

The stiffener 158 may be provided with an opening or a notch to allow passage of fasteners through the stiffener 158 to allow engagement between the member 152 and the cap.

FIG. 6A is a perspective view of a holder 160 mounted on a modular connector, in accordance with an embodiment.

The holder 160 may be a bracket and may be used to hold textiles, fabrics, wires, straps, and/or other accessories that may be used in combination with an outdoor structure formed using the modular connector 100. For example, a fabric (such as canvas) covering extending over the frame may be attached to the holder 160.

In various embodiments, apertures may be provided in the holder 160 to allow hooking directly on to the holder 160.

It is important to provide a separate holder because the modular connector 100 itself is configured to wrap around the frame members and achieve a compact and strong connection. Extraneous components protruding from the modular connector 100 may not be desirable unless selectively mountable and removable, as well as being aesthetically acceptable.

FIG. 6B is an exploded perspective view of the holder 160.

FIG. 6C is a rear perspective view of the holder 160.

FIG. 6D is a front perspective view of the holder 160.

The holder 160 comprises a pair of interlocking pieces 162A, 162B and a coupler 164.

The interlocking pieces 162A, 162B each have a corresponding end 166 that is suitable for being received into a slot 148. For example, the ends 166 may be tabs, hooks, or angular extensions suitable for being hooked into the slots 148 to mitigate movement of the ends 166 out of the corresponding slots 148. Opposing ends of the interlocking pieces 162A, 162B are shaped in a manner that is mutually complementary to allow interlocking. As shown in FIG. 6A-6D, the interlocking pieces 162A, 162B may be shaped to form complementary keyways that engage and disengage with each other in a horizontal direction. As such, the interlocking pieces 162A, 162B provide abutting stops to each other in the vertical direction.

The coupler 164 comprises a pair of pockets 168 defined by walls connected to each other via an intermediate connector 170. In various embodiments, walls and the intermediate connector 170 may be in unitary construction with each other. The pair of pockets 168 may be disposed at opposite ends of the coupler 164 such that the each of the pair of pockets 168 is proximal to a respective piece of the interlocking pieces 162A, 162B and distal from another one of the interlocking pieces 162A, 162B. Each pocket of the pair of pockets 168 may be open in a horizontal direction.

The pair of pockets 168 may have open ends disposed at opposite sides of the coupler 164, and closed ends disposed at opposite sides of the coupler 164. The opposite sides may be defined by vertical ends of the coupler 164 such that each pocket of the pair of pockets 168 defines a vertical stop in at least one vertical direction, at most one vertical direction, or in exactly one vertical direction for parts disposed therein.

Each of interlocking pieces 162A, 162B is received in a corresponding pocket of the pair of pockets 168, e.g. by horizontal or vertical sliding therein, to cause the coupler 164 to bi-directionally half-encase (or envelope) an interlocked piece defined by the interlocking of the interlocking pieces 162A, 162B. The mutually complementary keyways in the interlocking pieces 162A, 162B and the enveloping coupler 164 together prevent vertical movement.

Advantageously, a substantially rigid and robust holder may be achieved without using fasteners and at low cost, since such holder may be achieved with only three parts, each of which may be unitary or of unitary construction.

Advantageously, the holder 160 may be rapidly assembled and disassembled by a user for use. For example, the holder 160 may be assembled without the need for tools.

FIG. 7A is a perspective view of a modular connector 100A, in accordance with another embodiment.

The modular connector 100A has only a single secondary sleeve 104A that is orthogonal to the primary sleeve 102.

FIG. 7B is a perspective view of a modular connector 100B, in accordance with a further embodiment.

The modular connector 100B has only two secondary sleeves 104A, 140B that are mutually orthogonal and orthogonal to the primary sleeve 102.

FIG. 7C is a perspective view of a modular connector 100C, in accordance with yet a further embodiment.

The modular connector 100C has only four secondary sleeves 104A, 140B, 104C, 104D that form two pairs of mutually orthogonal sleeves, and which are all orthogonal to the primary sleeve 102.

FIG. 7D is a perspective view of a modular connector 100D, in accordance with yet another further embodiment.

The modular connector 100D has only two secondary sleeves 104A, 104D that are parallel to each other. The two secondary sleeves 104A, 104D are orthogonal to the primary sleeve 102 and disposed on opposite sides thereof.

The modular connectors 100A, 100B, 100C, 100D, may be reconfigured according to any one of the embodiments shown in FIGS. 7A-7D. For example, a secondary sleeve may be mounted on to the primary sleeve in FIG. 7A to obtain the modular connectors 100C, 100D of FIG. 7C or FIG. 7D.

FIG. 8 is a cross-sectional view, in perspective, of a secondary sleeve 104, in accordance with an embodiment. The secondary sleeve 104 in FIG. 8, may be suitable for coupling a secondary member non-perpendicularly to a primary member, e.g. for sloped roof joists. As shown in FIG. 8, the end plate 130 may be angled to form an angle 131 that is less than 90° (acute angle) and the plurality of tabs 132 may be axially spaced apart from the end plate 130.

FIG. 9 is a partial perspective view of a secondary sleeve 104, in accordance with an embodiment. The secondary sleeve 104 defines a plurality of tabs 132 that interlock with the plurality of slots 110, e.g. by hooking thereinto. The plurality of tabs 132 in FIG. 9 may each define a corresponding gap to catch onto the primary sleeve 102.

FIG. 10A is a perspective view of a secondary sleeve 104, in accordance with an embodiment.

FIG. 10B is a rear elevation of the secondary sleeve 104 of FIG. 10A.

The secondary sleeve 104 in FIGS. 10A-10B includes depression on each side thereof. In particular, grooves 146 are provided in between the slots and the end of the secondary sleeve 104 to center the member 154 inside the secondary sleeve 104.

FIG. 11A is a perspective view of another embodiment of a holder 160, in accordance with an embodiment.

FIG. 11B is an exploded perspective view of the holder 160 of FIG. 11A.

The holder in FIG. 11A-11B defines a single elongated pocket 168 defined by a wall having a U-shaped cross-section. The single elongated pocket 168 may be suitable to receive therein both interlocking pieces 162A, 162B. The interlocking pieces 162A, 162B define opposing ends that are mutually complementary dovetails so as to allow interlocking of these ends. The embodiment of the holder 160 in FIGS. 11A-11B may allow faster mounting and may achieve an improved appearance.

An example process of forming a structure may include the following steps: receiving the primary member 152 into the primary sleeve 102 via an open end thereof until contact is made with the stiffener 158, then driving fasteners (such as wood screws or the like) through all the apertures formed in the plurality of grooves 114 to lock the primary member 152 into place, then inserting the plurality of tabs 132 of a secondary sleeve 104 into the plurality of slots 110 to position the secondary sleeve 104, then driving fasteners (such as wood screws or the like) through the plurality of apertures 140 and the plurality of apertures 116 to attach the primary and secondary sleeves 102, 104 to each other, then receiving the secondary member 154 into the secondary sleeve 104, then driving fasteners (such as wood screws or the like) through all the apertures formed in the plurality of grooves 146 to lock the secondary member 154 into place.

In various embodiments, the holder 160 may include a plurality of embossments, e.g. two embossments, defined on one side of the holder and corresponding complementary protrusions facing the inside of the holder to facilitate engagement of the protrusions with apertures, e.g. circular apertures, in the interlocking pieces 162A, 162B.

It is understood that the primary and secondary sleeves are suitable for forming modular connectors to allow a variety of connectors to be formed via a much smaller set of unique connectors. In some cases, such connectors may then be welded, e.g. the edges of the primary and secondary sleeves may be suitable to allow wire welding to improve mating between sleeves. Further, in some cases, a manufacturing process may utilize the modular connectors, formed using the primary and secondary sleeves, to form integrated connectors. For example, once a modular connector is formed, the modular connector assembly may be transformed into a unitary component representing a desired connector by diffusion welding, or other methods of joining materials.

FIG. 12A is an exploded perspective view of a secondary sleeve 104, in accordance with an embodiment.

FIG. 12B is a perspective view of the secondary sleeve 104 of FIG. 12A.

The secondary sleeve 104 shown in the embodiment of FIGS. 12A-12B is constructed by joining two parts, a first sleeve part 104-1 and a second sleeve part 104-2.

Each of the sleeve parts 104-1, 104-2 may generally be in the form of an angle bracket, e.g. an L-shaped angle bracket. It is found particularly cost effective and otherwise advantageous to manufacture the sleeve 104 by welding the sleeve parts 104-1, 104-2 along edges defining corner edges of the sleeve 104. Advantageously, each sleeve part 104-1, 104-2 may be formed by bending a unitary sheet of metal or other material. In various embodiments, a unitarily constructed sleeve 104 may be achieved by joining two unitary sleeve parts 104-1, 104-2 by welding or otherwise fusing materials of the sleeve parts 104-1, 104-2 to each other, directly or indirectly.

As referred to herein, an angle bracket refers to a structure comprising two arms that meet at an angle to each other. As shown in FIGS. 12A-12B, each of the sleeve parts 104-1, 104-2 comprises two arms that meet at a substantially 90° angle. Such two arms are typically flat plates, e.g. sheet metal formed into a two arm shape with potentially additional variations, and may be substantially linear or straight. It is understood that the arms may be curved in some embodiments.

While modular connectors provide advantageous flexibility to a user, such configurational flexibility can increase the workload for a user by requiring repeating assembly steps. For example, a user may assemble a rectangular shade (formed with four horizontal frame members) supported on four vertical frame members using a set of four three-sleeved connectors that form tubular corners of the rectangular cover. An additional rectangular shade (formed with one of the four horizontal frame members and an additional three horizontal frame members) may then be connected to the original rectangular shade by using two additional three-sleeved connectors supported on two additional frame members and then providing two of the three-sleeved connectors with an extra sleeve. Further additional rectangular shades may be added in a similar manner. As such an array of rectangular shades may be formed using three-sleeved connectors, and four-sleeved connectors, or three-sleeved connectors with capacity to mount thereon an optional fourth sleeve.

It is found advantageous to utilize pre-constructed connectors with optional modularity in forming a structure to reduce user workload, reduce assembly time, and improve rigidity, stability, and/or strength (load-bearing capacity) of the structure. As described above, a three-sleeved corner connector with a capacity for mounting thereon an optional fourth sleeve may be particularly advantageous to have pre-constructed. Embodiments of three-sleeved corner connectors are described in the following pages.

FIG. 13 is a perspective view of a corner connector 200, in accordance with an embodiment.

The corner connector comprises three sleeves 204A, 204B, 204C, each of which defines a corresponding axis 106A, 106B, 106C. The sleeves 204A, 204B, 204C are non-parallel to each other, e.g. the axes 106A, 106B, 106C are mutually non-parallel. The sleeves 204A, 204B, 204C may be mutually orthogonal.

Each of the sleeves 204A, 204B, 204C is tubular so as to form a tubular corner 202 by interconnection of the sleeves 204A, 204B, 204C. The tubular corner 202 defines, and is formed between, an inner spine 208 and an outer spine 210. As referred to herein, inner spine 208 refers to an edge formed on the inside end of the tubular corner 202 and an outer spine 210 refers to an edge formed on the outside end of the tubular corner 202. The tubular corner 202 defines an interior 205 for receiving frame members therein for forming a corner of a structure using the corner connector 200.

Each of the sleeves 204A, 204B, 204C may define square cross-sections normal to their respective axis 106A, 106B, 106C.

It is understood that, in some embodiments, the sleeves 204A, 204B, 204C may be configured such that their interiors are not contiguous, i.e. the interior 205 may comprise two or more disjointed spaces in the interior of the corner connector 200.

The corner connector 200 comprises a plurality of apertures 116 suitable to receiving fasteners to attached sleeves of the corner connector 200 to the frame members insert thereinto.

In various embodiments, the sleeves 204A, 204B, 204C may include biting grooves.

FIGS. 14A-14C are respective perspective views of five successive stages of assembling or constructing a corner connector 200, in accordance with various embodiments.

FIGS. 15A-15C are respective perspective views of three successive stages of assembly of a structure 150 using the pre-constructed (or pre-assembled) corner connector 200 and frame members 152, 154, in accordance with an embodiment. For greater clarity, the frame members 152, 154 are only shown partially.

FIG. 16 is a cross-sectional view along the line 16-16 in FIG. 15C, in accordance with an embodiment.

Referring to a first stage of assembly illustrated in FIG. 14A, there is provided a first angle bracket 212 (or simply angle bracket 212). The angle bracket 212 may be suitable to be directly attached to the frame member 152 via insertion or reception into a sleeve formed with the angle bracket 212 and/or by directly fastening of the angle bracket 212 to the frame member 152.

The angle bracket 212 comprises a projection 222A and a bottom slot 218A formed on respective opposite arms 230A, 230B of the angle bracket 212.

Referring to a second stage of assembly illustrated in FIG. 14B, an angle bracket 214 is coupled to the angle bracket 212 via a side slot 220 of the angle bracket 214. The side slot 220 is dimensioned according to the projection 222A to securably receive the projection 222A therethrough. This allows the projection 222A to be received into interior 205 of the tubular corner 202 to couple the angle brackets 212, 214 to each other and to form the inner spine 208 of the inside end of the tubular corner 202.

The second angle bracket 214 is suitable to be directly attached to a frame member 152 proximal and non-parallel to the frame member 152 attached to the first angle bracket 212.

The angle bracket 214 further includes a corresponding bottom slot 218B. The projection 222B and the bottom slot 218B are formed on respective opposite arms 230A, 230B of the angle bracket 214.

Referring to a third stage of assembly illustrated in FIG. 14C, an angle bracket 216 is coupled to both the angle brackets 212, 214 via a plurality of projections 226 dimensioned according to bottom slots 218A, 218B so as to be securably received therethrough into the interior 205 of the tubular corner 202. As a result, the plurality of projections 226 overlap each of the projections 222A, 222B to obstruct the projections 222A, 222B to mitigate movement (indicated by the double-headed arrows in FIG. 14C) of the angle brackets 212, 214. This improves rigidity of the corner connector 200. In various embodiments, the plurality of projections 226 abut, frictionally engage with, and/or push against the projections 222A, 222B. Each projection 222A, 222B may have overlapped thereon a corresponding (vertical) projection of the plurality of projections 226. In various embodiments, each projection 222A, 222B may be spot welded to a corresponding (vertical) projection of the plurality of projections 226 to allow ease of assembly.

The third angle bracket 216 is suitable to directly attached to a frame member 152 proximal and non-parallel to the frame member 152 attached to the angle bracket 212 and the frame member 152 attached to the angle bracket 214. The third angle bracket 216 may comprise a pair of projections extending from a corresponding pair of arms of the third angle bracket 216.

Referring to the fourth and fifth stages of assembly in FIGS. 14D-14E, a rigid sheath 236 is attached, and extends opposite, to the angle brackets 212, 214, 216 to form the outer spine 210 of the outside end of the tubular corner 202 and to form the sleeves 204A, 204B, 204C. The sheath 236 may comprise three mutually orthogonal plates that are attached to each other.

As shown in FIGS. 14D-14E, the sheath 236 comprises a top sheath 232 and a side sheath 234.

The top sheath 232 may be attached to the angle brackets 212, 214 in the fourth stage of assembly in FIG. 14D along an edge 229. The side sheath 234 may be attached to the angle brackets 212, 214, 216 and the top sheath 232 along outer edges 231 of the corner connector 200, in the fifth stage of assembly in FIG. 14E.

In various embodiments, the side sheath 234 of the sheath 236 is welded to the angle brackets 212, 214, 216 and the top sheath 232 at the outer edges 231 to form a unitarily constructed sheath 236.

The sheath 236 defines a plurality of slots 110 suitable to receive a corresponding plurality of tabs 132 of sleeve 104 to couple the sleeve 104 to the corner connector 200. This allows attaching another frame member 152 by receiving the frame member 152 into the sleeve 104.

The angle brackets 212, 214 further comprise corresponding bottom projections 224A, 224B. While, in some embodiments, the bottom projections 224A, 224B may project outwardly from bottom arms of the angle brackets 212, 214, it is understood that the bottom projections 224A, 224B may not project outwardly from the bottom-most arms of the angle brackets 212, 214. In some embodiments, the bottom projection 224A may be formed on an arm of the angle bracket 212 opposite to the arm of the angle brackets 212 that has formed thereon (or has projecting therefrom) the projection 222A. In some embodiments, the bottom projection 224B may be formed on an arm of the angle bracket 214 opposite to the arm of the angle bracket 214 that has formed thereon the side slot 220. In various embodiment, the bottom projections 224A, 224B are formed on respective arms 230B of the angle brackets 212, 214 having corresponding bottom slots 218A, 218B.

As shown in FIGS. 14A-14D, the bottom projections 224A, 224B overlap (e.g. abut) each other in the interior 205 once the angle brackets 212, 214 are coupled to each other. In various embodiments, the bottom projections 224A, 224B abut, frictionally engage with, and/or push against each other. As a result, movement of the angle brackets 212, 214 may be mitigated along direction(s) indicated in FIG. 14B using double-headed arrows. Rigidity may thereby be improved. The bottom projections 224A, 224B may be spot welded to each other to allow ease of assembly. The bottom projections 224A, 224B may be aligned based on plurality of apertures thereon.

Referring to the movements indicated by double-headed arrows in FIGS. 14B-14C, advantageously, the projections 222A, 222B overlapping the plurality of projections 226 may mitigate movement in direction(s) that are non-parallel to the direction(s) in which movement is mitigated by overlapping of the bottom projections 224A, 224B. Rigidity may thereby be improved in a plurality of directions.

Furthermore, referring to FIG. 14C, the projection 222A may overlap the plurality of projections 226 to mitigate movement in a direction that is not parallel to a direction in which movement is mitigated by overlapping of the projection 222B with the plurality of projections 226. Consequently, movement of the angle brackets 212, 214 may be mitigated in at least three mutually non-parallel or three mutually orthogonal directions.

Referring to FIG. 14D, the bottom projections 224A, 224B may be fastened to each other. The plurality of projections 226 may be fastened to each of the projections 222A, 222B. Such fastening may be achieved using fasteners 228. The fasteners 228 may allow rigid fastening. In some embodiments, the bottom projections 224A, 224B may be spot welded to each other instead or additional to fastening. In various embodiments, spot welding may improve ease of assembly as it may enable holding various of the angle brackets 212, 214, 216 and/or the sheath 236 in place during assembly.

Referring FIG. 15A-15C, the angle brackets 212, 214, 216 may be fastened to each other. Each of the angle brackets 212, 214, 216 may include a corresponding one or more apertures to allow fastening therethrough of the frame members 152, 154. For example, the angle brackets 212, 214, 216 may be fastened to frame members via fasteners. Referring to FIG. 15C, a brace 242 may be attached to the sleeves 204B, 204C to improve rigidity of the structure 150 and/or to provide a holder with functionality similar to the holder 160 described above. In some embodiments, the one or more apertures on the projections may facilitate geometrically aligning the angle brackets relative to each other. In some embodiments, the projections may be attached to each other by welding rather than by fastening with fasteners. For example, the projections may be spot welded to each other instead or additional to fastening. In various embodiments, spot welding may improve ease of assembly as it may enable holding various components in place during assembly.

As shown in FIGS. 15A-15C, the corner connector 200 connects three frame members to each other to form a tubular corner 202 of the structure 150. The angle bracket 212 is directly attached to a first frame member 154. The angle bracket 214 is directly attached to a second frame member 154, which is proximal and non-parallel to the first frame member 154. The angle bracket 218 is directly attached to a third frame member 152, e.g. a vertical frame member or post, which is proximal and non-parallel to each of the first and second frame members 152. The three frame members may be mutually orthogonal. For example, the three frame members may be rigidly fastened to the corner connector 200.

Referring to FIGS. 14A-14D, the angle bracket 212 may further include a spacer 238. For example, the bottom projection 224A may form a bend at a terminal end thereof to form the spacer 238. This spacer 238 may extend non-parallel to or orthogonally away from the arm 230B.

As shown in FIG. 16, the spacer 238 extends towards the frame member 154 to abut the frame member 154 to form a gap 240 adjacent to the frame member 154, between the arm 230B and the frame member 154, in the interior 205. The spacer 238 may be dimensioned based on a position of the plurality of slots 110 such that the plurality of slots 110 open into the gap 240 after mounting of the frame member 154 into the corner connector 200. Advantageously, this allows the plurality of tabs 132 of the sleeve 104 to be inserted or received into the plurality of slots 110 of the sheath to allow positioning and engagement of the sleeve 104 with the corner connector 200 to allow coupling of the sleeve 104 to the corner connector 200 to form a four-corner connector.

In various embodiments, each of the projections 222A, 222B and the bottom projections 224A, 224B is planar tabular-shaped. In various embodiments, the projections 222A, 222B and the bottom projection 224A are mutually orthogonal. In various embodiments, the projections 222A, 222B and the bottom projection 224B are mutually orthogonal. In various embodiments, the bottom projections 224A, 224B are parallel to each other. In various embodiments, the projection 222A is parallel to one of the plurality of projections 226. In various embodiments, the projection 222B is parallel to one of the plurality of projections 226.

In various embodiments, the projections 222A, 222B, the plurality of projections 226, and/or the bottom projections 224A, 224B may be formed of plates (or be plate-like), and/or may be constructed of sheet metal. In various embodiments, each of the angle brackets 212, 214, 216 is of unitary construction and/or may be composed of sheet metal. For example, each of the angle bracket 212, 214, 216 may be composed of a corresponding single piece of sheet metal that is bent to achieve a desired geometry.

In various embodiments, the projections 222A, 222B, the plurality of projections 226, and/or the bottom projections 224A, 224B may define gaps between each other, i.e. each projection may be independent and not directly attached or connected to another projection.

In various embodiments, in the structure 150, the projections 222A, 222B and the plurality of projections 226 are vertically oriented (or vertical). In various embodiments, in the structure 150, the bottom projections 224A, 224B are horizontally oriented (or horizontal).

FIGS. 17A-17C are respective plan, rear elevation, and side elevation views of the angle bracket 212, in accordance with an embodiment.

FIGS. 18A-18C are respective perspective, front elevation, and side elevation views of the angle bracket 216, in accordance with an embodiment.

FIGS. 19A-19C are respective perspective, front elevation, and side elevation views of the angle bracket 216, in accordance with an embodiment.

FIGS. 20A-20B are respective perspective and plan views of the top sheath 232, in accordance with an embodiment.

FIGS. 21A-21C are respective perspective, plan, and side elevation view of the side sheath 234, in accordance with an embodiment.

As shown in FIGS. 17A-17C to FIGS. 21A-21C, each of the components, e.g. angle brackets 212, 214, 216 and/or the sheath 236, may comprise features 250 accurate positioning of components relative to each other. Such features 250 are shown as tabs that are complementary to components portions where material is removed to allow complementary pairing with the tabs.

In various embodiments, once components are positioned relative to each other, the angle brackets 212, 214, 216 and/or the sheath 236 are welded (stitch welded or spot welded) to one another or otherwise fused to one another. For example, the top sheath 232 may be welded to the angle brackets 212, 214 along the edge 229 and to the side sheath 234 along an edge of the edges 231. For example, the side sheath 234 may be welded to angle brackets 212, 214, 216 along the edges 231. In some embodiments, the top sheath 232 is not welded to any other component and is instead fastened to the frame members.

In various embodiments, projections may comprise corresponding steps 245 to form a space, e.g. a nook, to receive an opposing projection to facilitate abutment between projections to improve rigidity of the corner connector 200.

FIG. 22 is a flow chart of an example method 2200 of constructing a corner connector to connect a first frame member, a second frame member, and a third frame member to each other to form a tubular corner of a structure.

A step 2202 of the method 2200 includes receiving a first projection of a first angle bracket through a side slot of a second angle bracket to position the first projection inside the second angle bracket, to position a second projection of the second angle bracket inside the first angle bracket, and to secure the first angle bracket to the second angle bracket.

A step 2204 of the method 2200 includes receiving a plurality of projections of a third angle bracket through a first bottom slot of the first angle bracket and a second bottom slot of the second angle bracket to secure the third angle bracket to the first angle bracket and the second angle bracket, the first bottom slot and the first projection being formed on opposite arms of the first angle bracket, the second bottom slot and the second projection being formed on opposite arms of the second angle bracket.

A step 2206 of the method 2200 includes overlapping the plurality of projections against the first projection of the first angle bracket and a second projection of the second angle bracket to obstruct movement of the first angle bracket and the second angle bracket while the third angle bracket is secured to the first angle bracket and the second angle bracket.

A step 2208 of the method 2200 includes attaching a rigid sheath to the first angle bracket to form a first sleeve suitable to receive the first frame member.

A step 2210 of the method 2200 includes attaching the sheath to the second angle bracket to form a second sleeve suitable to receive the second frame member.

A step 2212 of the method 2200 includes attaching the sheath to the third angle bracket to form a third sleeve suitable to receive the third frame member.

Some embodiments of the method 2200 include fastening the plurality of projections to each of the first projection and the second projection.

In some embodiments of the method 2200, each of the first angle bracket, second angle bracket, third angle bracket, and sheath is of unitary construction.

In some embodiments of the method 2200, attaching the sheath to the first angle bracket includes continuously joining the sheath to the first angle bracket to unitarily construct the first sleeve.

In some embodiments of the method 2200, attaching the sheath to the second angle bracket includes continuously joining the sheath to the second angle bracket to unitarily construct the second sleeve.

In some embodiments of the method 2200, attaching the sheath to the third angle bracket includes continuously joining the sheath to the third angle bracket to unitarily construct the third sleeve.

In some embodiments of the method 2200, attaching the sheath to the first angle bracket includes welding the sheath to the first angle bracket to form a first pair of edges of the first sleeve.

In some embodiments of the method 2200, attaching the sheath to the second angle bracket includes welding the sheath to the second angle bracket to form a second pair of edges of the second sleeve.

In some embodiments of the method 2200, attaching the sheath to the third angle bracket includes welding the sheath to the third angle bracket to form a third pair of edges of the third sleeve.

In some embodiments of the method 2200, each of the first angle bracket, second angle bracket, third angle bracket, and sheath is composed of sheet metal.

In some embodiments of the method 2200, the sheath comprises a side sheath that defines an outer spine of the corner connector and a planar top sheath.

Some embodiments of the method 2200 include attaching the side sheath to the top sheath.

In some embodiments of the method 2200, overlapping of the first and the second projections mitigates movement of the first and the second angle brackets along a first direction.

Some embodiments of the method 2200 include overlapping a first bottom projection of the first angle bracket and a second bottom projection of the second angle bracket inside the corner connector while the first angle bracket is secured to the second angle bracket to mitigate movement of the first and the second angle brackets along a second direction non-parallel to the first direction.

Some embodiments of the method 2200 include fastening the first bottom projection to the second bottom projection.

As can be understood, the examples described above and illustrated are intended to be exemplary only. The embodiments described in this document provide non-limiting examples of possible implementations of the present technology. Upon review of the present disclosure, a person of ordinary skill in the art will recognize that changes may be made to the embodiments described herein without departing from the scope of the present technology. For example, the modular connector may be used to form angled corners for a roof truss, the sleeves of the modular connector may have non-square or non-rectangular cross-sections, self-tapping screws may be used to fasten sleeves to each other, and one or more welds may be provided at joints between the various sleeves to further improve the strength of connectors once assembled. Yet further modifications could be implemented by a person of ordinary skill in the art in view of the present disclosure, which modifications would be within the scope of the present technology.